Absorbent Article Having An Umbilical Notch Cut

ABSTRACT

A disposable absorbent article having a non-linear notch cut without the presence of a significantly laterally extending resulting piece. The resulting absorbent article having a front end edge and a back end edge which are complementary. The front end edge having at least three tangential points (a 1 , a 2 , b). Tangential point b is longitudinally inboard of a 1  and a 2 . The back end edge having at least three tangential points (x 1 , x 2 , y), wherein y is longitudinally outboard of x 1  and x 2 . The absorbent article being longitudinally folded about a first fold line. The first fold line may be drawn between points a 2  and x 2 . The absorbent article being longitudinally folded about a second fold line, said second fold line may be drawn between points a 1  and x 1 .

CROSS REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. application Ser. No.11/039,950, filed Jan. 20, 2005, the substance of which is incorporatedherein by reference.

FIELD OF THE INVENTION

This invention relates to absorbent articles which are particularlyadapted to newborn infants. More specifically, this invention relates todiapers having a U-notched cut without the presence of a significantlylaterally extending resulting piece that may create a safety risk.

BACKGROUND OF THE INVENTION

Newborn infants are exceptionally prone to inflammation, infection andcolonization of bacteria at the umbilicus as the residual, freshly cutumbilical cord offers an inviting site for bacterial invasion andfrictional irritation by the overlying diaper. The rubbing movement ofthe conventional diaper on an umbilicus which is still raw, as theinfant squirms, kicks and moves, often produces a sore place whichcauses the infant to be quite fretful. The umbilical area is noticeablyreddish and inflamed. Also, the overlying diaper can serve as a carrierof bacteria to the unhealed, cut cord and bring about an infection.

Due to the aforementioned reasons, conventional diapers which areparticularly adapted for newborns are often constructed with an openingthat is located centrally along the width of the end edge of the frontpanel of the diaper. Said opening is commonly referred to as a U-notch,V-notch or non-linear notch. In the creation of said non-linear notch, anon-linear cutting device is used. More specifically, individual diapersare often made from a plurality of continuous web materials that aresubsequently cut into discrete articles (i.e., diapers). During saidconventional non-linear notch cuts, however, the diaper often has asignificantly laterally extending resulting piece that may create asafety risk. What is needed is a diaper/cut design and process thatprovides a non-linear notch cut without the presence of a significantlylaterally extending resulting piece.

SUMMARY OF THE INVENTION

A disposable absorbent article having a longitudinal axis and a lateralaxis. The absorbent article further having a front end edge and a backend edge which are complementary in shape and are formed by a non-linearnotch cut; said front end edge having at least three tangential points(a₁, a₂, b). Tangential point b is longitudinally inboard of a₁ and a₂.The front end edge having at least two edge points (c₁, c₂), wherein:

-   -   (i) c₁ and c₂ are longitudinally inboard of a₁ and a₂, and    -   (ii) c₁ and c₂ are longitudinally equal or outboard of b.

The front end edge having a contour segment from said point a₁ to saidpoint c₁ which is a mirror image of a contour segment from said point a₁to said point b. The said front end edge having a path length measuredalong said contour segment from point a₁ to point c₁ which is less thanor equal to the path length measured along said contour segment frompoint a₁ to point b.

The back end edge having at least three tangential points (x₁, x₂, y),wherein y is longitudinally outboard of x₁ and x₂. The said back endedge having at least two edge points (z₁, z₂), wherein:

-   -   (i) z₁ and z₂ are longitudinally outboard of x₁ and x₂, and    -   (ii) z₁ and z₂ are longitudinally equal or inboard of y.

The back end edge has a contour segment from said point x₁ to said pointz₁ which is a mirror image of a contour segment from said point x₁ tosaid point y. The back end edge has a path length measured along saidcontour segment from point x₁ to point z₁ which is less than or equal tothe path length measured along said contour segment from point x₁ topoint y.

The absorbent article being longitudinally folded about a first foldline. The first fold line may be drawn between points a₂ and x₂. Theabsorbent article being longitudinally folded about a second fold line,said second fold line may be drawn between points a₁ and x₁.

Further, the absorbent article may have a longitudinal distance, d,which is measured between said tangential point b and said tangentialpoint a₁, wherein the longitudinal distance being from about 5 mm toabout 25 mm, preferably 10 mm.

Further, the absorbent article may have a lateral distance, f, which ismeasured between said fold lines, wherein the lateral distance beingfrom about 80 mm to about 100 mm, preferably 90 mm.

Further, the disposable absorbent article may be constructed as an opendiaper or pant.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter that is regarded as thepresent invention, it is believed that the invention will be more fullyunderstood from the following description taken in conjunction with theaccompanying drawings. None of the drawings are necessarily to scale.

FIG. 1 is a schematic, top view of continuous webs of materials havingears joined thereto, said webs being converted for the ultimatemanufacturing of discrete absorbent articles in accordance with thepresent invention;

FIG. 2 is a schematic, top view of the webs from FIG. 1 with foldinglines being depicted;

FIG. 3 is a schematic, top view of the webs from FIG. 2 with a firstportion being longitudinally folded about a first fold line;

FIG. 4 is a schematic, top view of the webs from FIG. 3 with a secondportion being longitudinally folded about a second fold line;

FIG. 5 is a schematic, top view of the webs from FIG. 4 with non-linearcut-lines shown;

FIG. 6 is a schematic, top view of the webs from FIG. 5 being separatedinto individual absorbent articles;

FIG. 7 is a close-up of the encircled region of FIG. 6;

FIG. 8 is a schematic, top view of an absorbent article from FIG. 6being unfolded; and

FIG. 9 is a schematic, top view of the absorbent article from FIG. 8showing critical dimensions in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION Definitions

The term “absorbent article” herein refers to devices which absorb andcontain body exudates and, more specifically, refers to devices whichare placed against or in proximity to the body of the wearer to absorband contain the various exudates discharged from the body, such as:incontinence briefs, incontinence undergarments, absorbent inserts,diaper holders and liners, feminine hygiene garments and the like. Saidabsorbent article may have an absorbent core having a garment surfaceand a body surface; a liquid permeable topsheet positioned adjacent saidbody surface of said absorbent core; and a liquid impermeable backsheetpositioned adjacent said garment surface of said absorbent core.

The term “disposable” is used herein to describe absorbent articleswhich generally are not intended to be laundered or otherwise restoredor reused as absorbent articles (i.e., they are intended to be discardedafter a single use and, preferably, to be recycled, composted orotherwise discarded in an environmentally compatible manner).

The term “diaper” herein refers to an absorbent article generally wornby infants and incontinent persons about the lower torso.

The term “pant”, as used herein, refers to disposable garments having awaist opening and leg openings designed for infant or adult wearers. Apant may be placed in position on the wearer by inserting the wearer'slegs into the leg openings and sliding the pant into position about thewearer's lower torso. A pant may be preformed by any suitable techniqueincluding, but not limited to, joining together portions of the articleusing refastenable and/or non-refastenable bonds (e.g., seam, weld,adhesive, cohesive bond, fastener, etc.). A pant may be preformedanywhere along the circumference of the article (e.g., side fastened,front waist fastened). While the term “pant” is used herein, pants arealso commonly referred to as “closed diapers”, “prefastened diapers”,“pull-on diapers”, “training pants” and “diaper-pants”. Suitable pantsare disclosed in U.S. Pat. No. 5,246,433, issued to Hasse, et al. onSep. 21, 1993; U.S. Pat. No. 5,569,234, issued to Buell et al. on Oct.29, 1996; U.S. Pat. No. 6,120,487, issued to Ashton on Sep. 19, 2000;U.S. Pat. No. 6,120,489, issued to Johnson et al. on Sep. 19, 2000; U.S.Pat. No. 4,940,464, issued to Van Gompel et al. on Jul. 10, 1990; U.S.Pat. No. 5,092,861, issued to Nomura et al. on Mar. 3, 1992; U.S. patentapplication Ser. No. 10/171,249, entitled “Highly Flexible And LowDeformation Fastening Device”, filed on Jun. 13, 2002; U.S. Pat. No.5,897,545, issued to Kline et al. on Apr. 27, 1999; U.S. Pat. No.5,957,908, issued to Kline et al on Sep. 28, 1999.

The term “machine direction (MD)” or “longitudinal” herein refers to adirection running parallel to the maximum linear dimension of thearticle and/or fastening material and includes directions within ±45° ofthe longitudinal direction.

The term “cross direction (CD)”, “lateral” or “transverse” herein refersto a direction which is orthogonal to the longitudinal direction.

The term “joined” encompasses configurations whereby an element isdirectly secured to another element by affixing the element directly tothe other element, and configurations whereby an element is indirectlysecured to another element by affixing the element to intermediatemember(s) which in turn are affixed to the other element.

Description

While absorbent articles are typically sold to the consumer as discretearticles packaged together, said absorbent articles are frequentlymanufactured from at least two continuous webs of materials. Forexample, FIG. 1 shows two exemplary continuous webs of materials,namely, a backsheet 13 and a topsheet 15. Said webs are unrolled andthen sent through several unit operations (also known as converting).During such converting, discrete parts may be placed and joined to oneor more of said webs. For instance, a first front ear 120 and a secondfront ear 122 may be joined interposed between backsheet 13 and topsheet15. Said front ears will subsequently serve as attachment means duringapplication of said absorbent article. Similarly, a first back ear 130and a second back ear 132 may be joined to backsheet 15. Said back earswork in conjunction with said front ears to serve as attachment meansduring application of said absorbent article. One skilled in the artwould appreciate that said ears may be joined to either or both webs inany combination and placement order. As can be seen in FIG. 1, at thisstage (i.e., prior to longitudinal folding) a first longitudinal edge116 and a second longitudinal edge 117 of said continuous web material15 are currently positioned most longitudinally outboard from thelongitudinal centerline 888. Within the region identified as absorbentarticle 200, a first front ear 220 and a second front ear 222 may besimilarly joined. Likewise, a first back ear 230 and a second back ear232 may be similarly joined. Lastly, a first longitudinal edge 216 and asecond longitudinal edge 217 of said continuous web material 15 arecurrently positioned most longitudinally outboard from the longitudinalcenterline 888. Within the region identified as absorbent article 300, afirst front ear 320 and a second front ear 322 may be similarly joined.Likewise, a first back ear 330 and a second back ear 332 may besimilarly joined. Lastly, a first longitudinal edge 316 and a secondlongitudinal edge 317 of said continuous web material are currentlypositioned longitudinally outboard from the longitudinal centerline 888.

Once the ears are joined, said webs are folded along at least twolongitudinally extending axes 1000, 1002 in directions as indicated byarrows 1010 and 1012, respectively. FIG. 2 shows said fold lines 1000and 1002 being located longitudinally outboard of the longitudinalcenterline 888 and longitudinally inboard of said first and secondlongitudinal edges. Said longitudinal centerline 888 extends in the MDdirection.

FIG. 3 shows the webs 13, 15 of FIG. 2 being folded about the firstlongitudinally extending axis 1000 in a direction as indicated by arrow1010. After being folded, the first longitudinal edges 116, 216, 316 aremoved longitudinally inboard. Further, a first fold edge 118 is formedwithin the region identified as absorbent article 100. Similarly, firstfold edges 218 and 318 are formed within regions 200 and 300,respectively.

FIG. 4 shows the webs 13, 15 of FIG. 3 being folded about the secondlongitudinally extending axis 1002 in a direction as indicated by arrow1012. After being folded, the second longitudinal edges 117, 217, 317are moved longitudinally inboard. Further, a second fold edge 119 isformed within the region identified as absorbent article 100. Similarly,second fold edges 219 and 319 are formed within regions 200 and 300,respectively.

FIG. 5 shows the webs 13, 15 of FIG. 4 being cut along cut-lines 2000.Said cut-lines 2000 may be non-linear across the longitudinal axis ofsaid webs. The geometrical criticalities of said cut-lines 2000 will bediscussed later. Said cut-lines may be a 100% severing of said webs or aless than 100% perforation of said webs. Said cut-lines may be createdby any suitable technique including, but not limited to, rotary knifeblade, reciprocating knife blade, air knife and laser.

FIG. 6 shows the cut webs 13, 15 of FIG. 5 being separated into discreteabsorbent articles 100, 200, 300. Once separated, said discreteabsorbent articles have complementary front and back end edges. Forexample, absorbent article 100 has a front end edge 140 and a back endedge 150. The geometries of said edges complement one another. Morespecifically, front end edge 140 has a U-notched portion 142 so as toprovide physical clearance to the naval of the newborn wearer, whilesaid back end edge 150 has a U-shaped protruding section 152 whichpositions itself up the backside of the wearer. The geometries of saidedges must be complementary otherwise a scrap piece requiring removalduring processing would result. FIG. 7 shows a close-up view of a regionwithin FIG. 6 so as to provide a more detailed view of the folded andcut portion along back end edge 150.

FIG. 8 shows absorbent article 100 of FIG. 6 being unfolded similar tothat of the unfolding performed by a consumer after removing saidarticle from its packaging. In this unfolded state, first longitudinaledge 116 and second longitudinal edge 117 are now most longitudinallyoutboard. Along the back end edge 150, a laterally extending piece ofmaterial 199 is formed and shaped as a result of the prior fold andU-notch cut. In this exemplary novel embodiment, said laterallyextending piece of material 199 is not aesthetically unpleasing nor doesit present a safety concern as discussed above. So long as the u-notchcut conforms to criticalities depicted in FIG. 9, the resultingextending piece 199 will not present such a safety concern.

FIG. 9 shows the unfolded absorbent article of FIG. 8 with the variouscritical dimensions highlighted. For example, front end edge 140 has atleast three tangential points identified as a₁, a₂, and b, wherein b islongitudinally inboard of a₁ and a₂. Further, front end edge 140 has atleast two edge points identified as c₁ and c₂, wherein (i) c₁ and c₂ arelongitudinally inboard of a₁ and a₂ and (ii) c₁ and c₂ arelongitudinally equal or outboard of b. Additionally, contour segment a-c(measured along the contour of end edge 140 between point a and point c)is a mirror image of contour segment a-b [measured along the contour offront end edge 140 between point a and point b]. Lastly, path length ofcontour segment a-c is less than or equal to the path length of contoursegment a-b. As it relates to the complementary cut of back end edge150, back end edge 150 has at least three tangential points identifiedas x₁, x₂ and y, wherein y is longitudinally outboard of x₁ and x₂.Further, back end edge 150 has at least two edge points identified as z₁and z₂, wherein (i) z₁ and z₂ are longitudinally outboard of x₁ and x₂and (ii) z₁ and z₂ longitudinally equal or inboard of y. Additionally,contour segment x-z (measured along the contour of back end edge 150between point x and point z) is a mirror image to contour segment x-y[measured along the contour of back end edge 150 between point x andpoint y]. Lastly, path length of contour segment x-z is less than orequal to the path length of contour segment x-y. Finally, fold line 1000may be drawn between points a₂ and x₂ and fold line 1002 may be drawnbetween points a₁ and x₁.

While the present invention may be appreciated as long as the abovegeometrical criticalities are met, it may be desirable to design adisposable diaper to have a longitudinal distance, d, between tangentialpoint b and tangential points a₁, a₂ range from about 5 mm to about 25mm, preferably 10 mm. Further, it may be desirable to have a lateraldistance, f, between said fold lines range from about 80 mm to about 100mm, preferably 90 mm.

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present invention.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

For example, one skilled in the art would appreciate that the presentinvention may be practiced with absorbent articles having a variety oftype of fasteners. Further, the absorbent article may be an open diaperor a pant.

For example, the front ears may be moved longitudinally inboard so asnot to be severed during the U-notch cut, unlike that shown theexemplary embodiment of FIGS. 5-9 wherein a portion of the front ears issevered and left sandwiched between the material layers of the precedingdiaper.

1. A disposable absorbent article having a longitudinal axis and alateral axis comprising: a front end edge and a back end edge which arecomplementary in shape and are formed by a non-linear notch cut; saidfront end edge having at least three tangential points (a₁, a₂, b),wherein b is longitudinally inboard of a₁ and a₂; said front end edgehaving at least two edge points (c₁, c₂), wherein: (iii) c₁ and c₂ arelongitudinally inboard of a₁ and a₂, and (iv) c₁ and c₂ arelongitudinally equal or outboard of b; said back end edge having atleast three tangential points (x₁, x₂, y), wherein y is longitudinallyoutboard of x₁ and x₂; said back end edge having at least two edgepoints (z₁, z₂), wherein: (iii) z₁ and z₂ are longitudinally outboard ofx₁ and x₂, and (iv) z₁ and z₂ are longitudinally equal or inboard of y;said back end edge has a contour segment from said point x₁ to saidpoint z₁ which is a mirror image of a contour segment from said point x₁to said point y; wherein the front end edge is configured to fit a navalof a wearer of the absorbent article.
 2. The disposable absorbentarticle according to claim 1 further comprising a longitudinal distance,d, which is measured between said tangential point b and said tangentialpoint a₁, said longitudinal distance being from about 5 mm to about 25mm.
 3. The disposable absorbent article according to claim 1 furthercomprising a longitudinal distance, d, which is measured between saidtangential point b and said tangential point a₁, said longitudinaldistance being about 10 mm.
 4. The disposable absorbent articleaccording to claim 1 said absorbent article being longitudinally foldedabout a first fold line, wherein said first fold line is drawn betweenpoints a₂ and x₂, said absorbent article being longitudinally foldedabout a second fold line, wherein said second fold line is drawn betweenpoints a₁ and x₁, and further comprising a lateral distance, f, which ismeasured between said fold lines, said lateral distance being from about80 mm to about 100 mm.
 5. The disposable absorbent article according toclaim 4 further comprising a lateral distance, f, which is measuredbetween said fold lines, said lateral distance being about 90 mm.
 6. Thedisposable absorbent article according to claim 1 wherein said absorbentarticle is an open diaper.
 7. The disposable absorbent article accordingto claim 1 wherein said absorbent article is a pant.
 8. The disposableabsorbent article according to claim 1 further comprising an absorbentcore having a garment surface and a body surface; a liquid permeabletopsheet positioned adjacent said body surface of said absorbent core; aliquid impermeable backsheet positioned adjacent said garment surface ofsaid absorbent core; said topsheet and backsheet together forming saidfront end edge and said back end edge after having been cut along anon-linear notch cut-line.
 9. The disposable absorbent article accordingto claim 8 wherein said absorbent article is an open diaper.
 10. Thedisposable absorbent article according to claim 8 wherein said absorbentarticle is a pant.